Platinum-ruthenium-nickel fuel cell electrocatalyst

ABSTRACT

A catalyst suitable for use in a fuel cell, especially as an anode catalyst, that contains platinum, ruthenium, and nickel, wherein the nickel is at a concentration that is less than about 10 atomic percent.

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is a continuation of U.S. application Ser. No.10/223,767, filed Aug. 20, 2002, which is a divisional of U.S.Application Ser. No. 09/513,559, filed Feb. 25, 2000, U.S. Pat. No.6,517,965, which claims the benefit of U.S. Provisional Application60/121,970, filed Feb. 26, 1999, each of which is hereby incorporatedherein by reference.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

[0002] This was made with Government support under grant numberDE-FG03-97ER82492 awarded by the Department of Energy. The Governmenthas certain rights in this invention.

BACKGROUND OF THE INVENTION

[0003] 1. Field of the Invention

[0004] The present invention relates to Group VIII metal alloycatalysts, especially to platinum, ruthenium and nickel alloy catalystscompositions, which are useful in fuel cell electrodes and othercatalytic structures.

[0005] 2. Description of Related Technology

[0006] A fuel cell is an electrochemical device for directly convertingthe chemical energy generated from an oxidation-reduction reaction of afuel such as hydrogen or hydrocarbon-based fuels and an oxidizer such asoxygen gas (in air) supplied thereto into a low-voltage direct current.Thus, fuel cells chemically combine the molecules of a fuel and anoxidizer without burning, dispensing with the inefficiencies andpollution of traditional combustion.

[0007] A fuel cell is generally comprised of a fuel electrode (anode),an oxidizer electrode (cathode), an electrolyte interposed between theelectrodes (alkaline or acidic), and means for separately supplying astream of fuel and a stream of oxidizer to the anode and the cathode,respectively. In operation, fuel supplied to the anode is oxidizedreleasing electrons which are conducted via an external circuit to thecathode. At the cathode the supplied electrons are consumed when theoxidizer is reduced. The current flowing through the external circuitcan be made to do useful work.

[0008] There are several types of fuel cells, including: phosphoricacid, molten carbonate, solid oxide, potassium hydroxide, and protonexchange membrane. A phosphoric acid fuel cell operates at about160-220° C., and preferably at about 190-200° C. This type of fuel cellis currently being used for multi-megawatt utility power generation andfor co-generation systems (i.e., combined heat and power generation) inthe 50 to several hundred kilowatts range.

[0009] In contrast, proton exchange membrane fuel cells use a solidproton-conducting polymer membrane as the electrolyte. Typically, thepolymer membrane must be maintained in a hydrated form during operationin order to prevent loss of ionic conduction which limits the operationtemperature typically to about 70-120° C. depending on the operatingpressure, and preferably below about 100° C. Proton exchange membranefuel cells have a much higher power density than liquid electrolyte fuelcells (e.g., phosphoric acid), and can vary output quickly to meetshifts in power demand. Thus, they are suited for applications such asin automobiles and small scale residential power generation where quickstartup is required.

[0010] Conventional fuel cells use hydrogen gas as the fuel. Purehydrogen gas, however, is difficult and costly to supply. Thus, hydrogengas is typically supplied to a fuel cell using a reformer, whichsteam-reforms methanol and water at 200-300° C. to a hydrogen-rich fuelgas containing carbon dioxide. Theoretically, the reformate gas consistsof 75 vol % hydrogen and 25 vol % carbon dioxide. In practice, however,this gas also contains nitrogen, oxygen and, depending on the degree ofpurity, varying amounts of carbon monoxide (up to 1 vol %). This processis also complex, adds cost and has the potential for producingundesirable pollutants. The conversion of a liquid fuel directly intoelectricity would be desirable, as then a high storage density, systemsimplicity and retention of existing fueling infrastructure could becombined. In particular, methanol is an especially desirable fuelbecause it has a high energy density, a low cost and is produced fromrenewable resources. Thus, a relatively new type of fuel cell has beenthe subject of a great amount of interest—the direct methanol fuel cell.In a direct methanol fuel cell, the overall process that occurs is thatmethanol and oxygen react to form water and carbon dioxide andelectricity, i.e., methanol combustion.

[0011] For the oxidation and reduction reactions in a fuel cell toproceed at useful rates, especially at operating temperatures belowabout 300° C., electrocatalyst materials are required at the electrodes.Initially, fuel cells used electrocatalysts made of a single metal,usually platinum (Pt), palladium (Pd), rhodium (Rh), iridium (Ir),osmium (Os), silver (Ag) or gold (Au) because they are able to withstandthe corrosive environment—platinum being the most efficient and stablesingle-metal catalyst for fuel cells operating below about 300° C. Whilethese elements were first used in solid form, later techniques weredeveloped to disperse these metals over the surface of electricallyconductive supports (e.g., carbon black) to increase the surface area ofthe catalyst which in turn increased the number of reactive sitesleading to improved efficiency of the cell. Nevertheless, fuel cellperformance typically declines over time because the presence ofelectrolyte, high temperatures and molecular oxygen dissolve thecatalyst and/or sinter the dispersed catalyst by surface migration ordissolution/re-precipitation (see, e.g., U.S. Pat. No. 5,316,990).

[0012] Although platinum is a good catalyst, concentrations of carbonmonoxide (CO) above about 10 ppm in the fuel can rapidly poison thecatalyst surface. As a result, platinum is a poor catalyst if the fuelstream contains carbon monoxide (e.g., reformed-hydrogen gas typicallyexceeds 100 ppm). Liquid hydrocarbon-based fuels (e.g., methanol)present an even greater poisoning problem. Specifically, the surface ofthe platinum becomes blocked with the adsorbed intermediate, carbonmonoxide (CO). It has been reported that H₂O plays a key role in theremoval of such poisoning species in accordance with the followingreactions:

Pt+CH₃OH→Pt—CO+4H⁺+4e⁻  (1)

Pt+H₂O→Pt—OH+H⁺+e⁻  (2)

Pt—CO+Pt—OH→2Pt+CO₂+H⁺+e⁻  (3).

[0013] As indicated by the foregoing reactions, the methanol is adsorbedand partially oxidized by platinum on the surface of the electrode (2).Adsorbed OH, from the hydrolysis of water (3), reacts with the adsorbedCO to produce carbon dioxide and a proton. However, platinum does notadsorb H₂O species well at the potentials fuel cell electrodes operate(e.g., 200 mV-1.5 V). As a result, step (3) is the slowest step in thesequence, limiting the rate of CO removal thereby poisoning thecatalyst. This applies in particular to a Proton exchange membrane fuelcell which is especially sensitive to CO poisoning as a result of itslow operating temperatures.

[0014] One technique for alleviating fuel cell performance reduction dueto anode CO poisoning is to employ an anode electrocatalyst which isitself more poison tolerant, but which still functions as a hydrogenoxidation catalyst in the presence of carbon monoxide. It is known thatthe tolerance of platinum poisoning by carbon monoxide is improved byalloying the platinum with ruthenium, preferably compositions centeredaround 50:50 atomic ratio (see, e.g., D. Chu and S. Gillman, J.Electrochem. Soc. 1996,143, 1685).

[0015] It has been reported that the success of the platinum-rutheniumcatalyst alloys is based on the ability of ruthenium to adsorb H₂Ospecies at potentials where methanol is adsorbing on the platinum andfacilitate the carbon monoxide removal reaction. This dual function,that is, to adsorb both reactants on the catalyst surface on adjacentmetal sites, is known as the bifunctional mechanism in accordance withthe following reaction:

Pt—CO+Ru—OH→Pt+Ru+CO₂+H⁺+e⁻  (4).

[0016] It has been suggested that having platinum and ruthenium inadjacent sites forms an active site on the catalyst surface wheremethanol is oxidized in a less poisoning manner because the adjacentmetal atoms are more efficiently adsorbing the methanol and the waterreactants.

[0017] Although knowledge of phase equilibria and heuristic bondstrength/activity relationships provide some guidance in the search formore effective catalyst compositions, there is at present no way tocalculate the chemical composition of different metals that will affordthe best catalyst activity for the direct methanol-air fuel cellreaction. As such, the search continues for stable, CO poisoningresistant and less costly catalysts having increased electrochemicalactivities.

BRIEF SUMMARY OF THE INVENTION

[0018] Among the objects of the invention are the preparation ofcatalysts based on platinum, ruthenium and nickel which have a highresistance to poisoning by carbon monoxide thereby improving theefficiency of a fuel cell, decreasing the size of a fuel cell andreducing the cost of operating a fuel cell.

[0019] Briefly, therefore, the present invention is directed to acatalyst for use in electrochemical reactor devices. The catalystcontains platinum, ruthenium, and nickel, wherein the nickel is at aconcentration that is less than about 10 atomic percent.

[0020] The present invention is also directed to a metal alloycontaining platinum, ruthenium and nickel, wherein the concentration ofnickel is less than about 10 atomic percent.

[0021] Additionally, the present invention is directed to a supportedelectrocatalyst powder for use in electrochemical reactor devices. Thesupported electrocatalyst powder comprises a catalyst on electricallyconductive supports, wherein the catalyst contains platinum, ruthenium,and nickel, and wherein the nickel is at a concentration that is lessthan about 10 atomic percent.

[0022] Further, the present invention is directed to a fuel cellelectrode that comprises a catalyst dispersed on the surface of anelectrically conductive support. The catalyst contains platinum,ruthenium and nickel, wherein the nickel is at a concentration that isless than about 10 atomic percent.

[0023] The present invention is also directed to a fuel cell. The fuelcell comprises an anode, a cathode, a proton exchange membrane betweenthe anode and the cathode, and a catalyst for the catalytic oxidation ofa hydrogen-containing fuel. The catalyst contains platinum, rutheniumand nickel, wherein the nickel is at a concentration that is less thanabout 10 atomic percent.

[0024] The foregoing and other features and advantages of the presentinvention will become more apparent from the following description andaccompanying drawing.

BRIEF DESCRIPTION OF THE DRAWINGS

[0025]FIG. 1 is a schematic structural view showing essential members ofa methanol fuel cell.

[0026]FIG. 2 is a side view of a methanol fuel cell.

[0027]FIG. 3 is a graph comparing the catalytic activity, at a constantvoltage and as a function of time, of several alloy compositionsincluding a PtRu binary alloy and PtRuNi ternary alloys. Only the PtRuNialloy compositions on Electrodes #2-#11 are within the scope of theclaimed invention.

[0028]FIG. 4 is a graph comparing the catalytic activity of a PtRuNiternary alloy composition to a PtRu binary composition as a function ofvoltage.

DETAILED DESCRIPTION OF THE INVENTION

[0029] The present invention is directed to a multi-component Group VIIImetal alloy composition for use in fuel cells. In particular, thepresent invention is directed to ternary alloy compositions consistingessentially of platinum, ruthenium and nickel. Surprisingly, PtRuNiternary alloys possess catalytic activity with less cost thanplatinum-ruthenium binary alloys. The composition of the PtRuNi ternaryalloys is based in part on the desired catalytic activity and cost. Ingeneral, the catalytic activity decreases with increasing concentrationsof nickel. As such, the concentration of nickel is preferably less thanabout 30 atomic percent, more preferably less than about 20 atomicpercent, and still more preferably less than about 10 atomic percent.Likewise, the cost of a ternary alloy decreases with increasing nickelconcentration. Consequently, the concentration of nickel is preferablyat least about 1 atomic percent, more preferably at least about 2 atomicpercent, and still more preferably at least about 4 atomic percent. Insome applications, e.g., when cost constraints are particularlyimportant, the concentration of nickel is preferably at least about 10atomic percent. Thus, the composition of a PrRuNi ternary alloy catalystis selected to meet the application requirements.

[0030] In one embodiment of the present invention, therefore, the PtRuNiternary alloy contains, in atomic percentages, about 40% to about 70%platinum, about 30% to about 50% ruthenium and less than about 30%nickel, preferably less than about 20%, more preferably less than about10%. In another embodiment of the present invention, the PtRuNi ternaryalloy contains, in atomic percentages, about 45% to about 65% platinum,about 35% to about 50% ruthenium and less than about 20% nickel,preferably less than about 10% nickel. In a further embodiment of thepresent invention, the PtRuNi ternary alloy contains, in atomicpercentages, about 50% to about 60% platinum, about 40% to about 50%ruthenium and less than about 10% nickel. Specific alloys which havebeen found to exhibit methanol oxidation activity include the alloyscorresponding the empirical formula Pt_(x)Ru_(y)Ni_(1-x-y) wherein x andy have the following values. X Y 54 40 51 43

[0031] Although the PtRuNi ternary alloy compositions of the presentinvention can be used in a phosphoric acid fuel cell, they areparticularly useful in a direct methanol fuel cell. As shown in FIG. 1and FIG. 2, a direct methanol fuel cell has a methanol electrode (fuelelectrode or anode) 2 and an air electrode (oxidizer electrode orcathode) 3. In between the electrodes, a proton exchange membrane 3serves as an electrolyte.

[0032] Preferably, in a fuel cell according to the present invention,the proton exchange membrane 1, the anode 2 and the cathode 3 areintegrated into one body, and thus there is no contact resistancebetween the electrodes 2 and 3 and the proton exchange membrane 1.Current collectors 4 and 5 are at the anode and cathode, respectively. Amethanol fuel chamber is indicated by numeral 8 and an air chamber isindicated by numeral 9. Numeral 6 is a sealant for the methanol fuelchamber and numeral 7 is a sealant for the air chamber. It is desirableto use a strongly acidic ion exchange membrane (e.g., perfluorosulphonicacid based membranes are widely used).

[0033] In general, electricity is generated by methanol combustion(i.e., methanol and oxygen react to form water, carbon dioxide andelectricity). This is accomplished in the above-described fuel cell byintroducing the methanol into the methanol fuel chamber 8, while oxygen,preferably air is introduced into the air chamber 9, whereby an electriccurrent can be immediately withdrawn therefrom into an outer circuit.Ideally, the methanol is oxidized at the anode to produce carbon dioxidegas, hydrogen ions and electrons. The thus formed hydrogen ions migratethrough the strongly acidic proton exchange membrane 1 and react withoxygen and electrons from the outer circuit at the cathode 3 to formwater. Typically, the methanol is introduced as a dilute acidic solutionto enhance the chemical reaction thereby increasing power output (e.g.,a 0.1 M methanol/0.5 M sulfuric acid solution).

[0034] Typically, the proton exchange membranes must remain hydratedduring operation of the fuel cell in order to prevent loss of ionicconduction, thus the membrane is preferably heat-resistant up to about100-120° C. Proton exchange membranes usually have reduction andoxidation stability, resistance to acid and hydrolysis, sufficiently lowelectrical resistivity (e.g., <10 Ω·cm), and low hydrogen or oxygenpermeation. Additionally, proton exchange membranes are usuallyhydrophilic, this ensures proton conduction (by reversed diffusion ofwater to the anode), and prevents the membrane from drying out therebyreducing the electrical conductivity. For the sake of convenience, thelayer thickness of the membranes is typically between 50 and 200 μm. Ingeneral, the foregoing properties are achieved with materials which haveno aliphatic hydrogen-carbon bonds, which, for example, is achieved byreplacing hydrogen with fluorine or by the presence of aromaticstructures; the proton conduction results from the incorporation ofsulfonic acid groups (high acid strength). Suitable proton-conductingmembranes also include perfluorinated sulfonated polymers such asNafion® and its derivatives produced by E.I. du Pont de Nemours & Co.,Wilmington, Del. Nafion® is based on a copolymer made fromtetrafluoroethylene and perfluorovinylether, and is provided withsulfonic groups working as ion-exchanging groups. Other suitable protonexchange membranes are produced with monomers such as perfluorinatedcompounds (e.g., octafluorocyclobutane and perfluorobenzene), or evenmonomers with C—H bonds which, in a plasma polymer, do not form anyaliphatic H atoms which could constitute attack sites for oxidativebreakdown.

[0035] In general, the electrodes of the present invention comprise anelectrically conductive material and are in contact with the PtRuNiternary catalyst of the present invention. The electrically conductivesupport is typically inorganic, preferably a carbon support. The carbonsupports may be predominantly amorphous or graphitic. They may beprepared commercially, or specifically treated to increase theirgraphitic nature (e.g., heat treated at a high temperature in vacuum orin an inert gas atmosphere) thereby increasing corrosion resistance. Forexample, it may be oil furnace black, acetylene black, graphite paper,carbon fabric or carbon aerogel. Preferably, the electrode is designedto increase cell efficiency by enhancing contact between the reactant(i.e., fuel or oxygen), the electrolyte and the electrocatalyst. Inparticular, porous or gas diffusion electrodes are typically used sincethey allow the fuel/oxidizer to enter the electrode from the face of theelectrode exposed to the reactant gas stream (back face), and theelectrolyte to penetrate through the face of the electrode exposed tothe electrolyte (front face), and products, particularly water todiffuse out of the electrode. Preferably, carbon black supports have aBrunauer, Emmett and Teller (BET) surface area of between 0 and 2000m²/g, and preferably between 30 and 400 m²/g, more preferably between 60to 250 m²/g. On the other hand, the carbon aerogel preferably has anelectrical conductivity of between 10⁻² and 10³ Ω⁻·cm⁻¹ and a density ofbetween 0.06 and 0.7 g/cm³; the pore size is between 20 and 100 nm(porosity up to about 95%).

[0036] Preferably, the proton exchange membrane, electrodes and catalystmaterials are in contact. This is generally accomplished by depositingthe catalyst either on the electrode, or the proton exchange membrane,and then the electrode and membrane placed in contact. The alloycatalysts of this invention can be deposited on either substrate by avariety of methods, including, plasma deposition, powder application,chemical plating, and sputtering. Plasma deposition generally entailsdepositing a thin layer (e.g., between 3 and 50 μm, preferably between 5and 20 μm) of a catalyst composition on the membrane using low-pressureplasma. By way of example, an organic platinum compound such astrimethylcyclopentadienylplatinum is gaseous between 10⁻⁴ and 10 mbarand can be excited using radio-frequency, microwaves or an electroncyclotron resonance transmitter to deposit platinum on the membrane.According to another procedure, catalyst powder is distributed onto theproton exchange membrane surface and integrated at an elevatedtemperature under pressure. If, however, the amount of catalystparticles exceeds about 2 mg/cm² the inclusion of a binder such aspolytetrafluoroethylene is common. Further, the catalyst may be platedwith dispersed relatively small particles, e.g., about 20-200 Å, morepreferably about 20-100 Å. This increases the catalyst surface areawhich in turn increases the number of reaction sites leading to improvedcell efficiency. In one such chemical plating process, for example, apowdery carrier material such as conductive carbon black is contactedwith an aqueous solution or aqueous suspension (slurry) of compounds ofmetallic components constituting the alloy to permit adsorption orimpregnation of the metallic compounds or their ions on or in thecarrier. Then, while the slurry is stirred at high speed, a dilutesolution of suitable fixing agent such as ammonia, hydrazine, formicacid or formalin is slowly added dropwise to disperse and deposit themetallic components on the carrier as insoluble compounds or partlyreduced fine metal particles.

[0037] The surface concentration of catalyst on the membrane orelectrode is based in part on the desired power output and cost for aparticular fuel cell. In general, power output increases with increasingconcentration, however, there is a level beyond which performance is notimproved. Likewise, the cost of a fuel cell increases with increasingconcentration. Thus, the surface concentration of catalyst is selectedto meet the application requirements. For example, a fuel cell designedto meet the requirements of a demanding application such as an outerspace vehicle will usually have a surface concentration of catalystsufficient to maximize the fuel cell power output. Preferably, thedesired power output is obtained with as little catalyst as possible.Typically, it is desirable that about 0.25 to about 6 mg/cm² of catalystparticles be in contact with the electrodes. If the surfaceconcentration of catalyst particles is less than about 0.25 mg/cm², thecell performance usually declines, whereas, above about 6 mg/cm² thecell performance is usually not improved.

[0038] To promote contact between the collector, electrode, catalyst andmembrane, the layers are usually compressed at high temperature. Thehousings of the individual fuel cells are configured in such a way thata good gas supply is ensured, and at the same time the product water canbe discharged properly. Typically, several fuel cells are joined to formstacks, so that the total power output is increased to economicallyfeasible levels.

[0039] In general, the ternary catalyst and electrodes of the presentinvention may be used to catalyze any fuel containing hydrogen (e.g.,hydrogen and reformated-hydrogen fuels). The improved catalytic activityof the PtRuNi ternary alloys, however, are particularly realized in thecatalysis of hydrocarbon-based fuels. Applicable hydrocarbon-based fuelsinclude saturated hydrocarbons such as methane (natural gas), ethane,propane and butane; garbage off-gas; oxygenated hydrocarbons such asmethanol and ethanol; and fossil fuels such as gasoline and kerosene;and mixtures thereof. The most preferred fuel, however, is methanol.

[0040] To achieve the full ion-conducting property of proton exchangemembranes, suitable acids (gases or liquids) are typically added to thefuel. For example, SO₂, SO₃, sulfuric acid, trifluoromethanesulfonicacid or the fluoride thereof, also strongly acidic carboxylic acids suchas trifluoroacetic acid, and volatile phosphoric acid compounds may beused (see, e.g., “Ber. Bunsenges. Phys. Chem.”, Volume 98 (1994), pages631 to 635).

Definitions

[0041] Activity is defined as the maximum sustainable, or steady state,current (Amps) obtained from the catalyst, when fabricated into anelectrode, at a given electric potential, or efficiency (Volts).Additionally, because of differences in the geometric area ofelectrodes, when comparing different catalysts, activity is oftenexpressed in terms of current density (A/cm²).

EXAMPLE 1

[0042] A tremendous amount of research has concentrated on exploring theactivity of surface modified binary, and to a much lesser extentternary, alloys of platinum in an attempt to both increase theefficiency of and reduce the amount of precious metals in the anode partof the fuel cell. Although electrodeposition was explored as a route tothe synthesis of anode materials (see, e.g., F. Richarz et al. SurfaceScience, 1995, 335, 361), only a few compositions were actuallyprepared, and these compositions were made using traditional singlepoint electrodeposition techniques.

[0043] In contrast, the catalyst alloy compositions of this inventionwere prepared using the combinatorial techniques disclosed in U.S.patent application Ser. No. 09/119,187, filed Jul. 20, 1998.Specifically, an array of independent electrodes (with areas of betweenabout 1 and 2 mm²) were fabricated on inert substrates (e.g., glass,quartz, sapphire alumina, plastics, and thermally treated silicon). Theindividual electrodes were located substantially in the center of thesubstrate, and were connected to contact pads around the periphery ofthe substrate with wires. The electrodes, associated wires, and contactpads were fabricated from conducting materials (e.g., gold, silver,platinum, copper or other commonly used electrode materials). In apreferred embodiment, the arrays were fabricated on standard 3″ (about7.5 cm) thermally oxidized single crystal silicon wafers, and theelectrodes were gold with surface areas of about 1.26 mm².

[0044] A patterned insulating layer covered the wires and an innerportion of the peripheral contact pads, but left the electrodes and theouter portion of the peripheral contact pads exposed (preferablyapproximately half of the contact pad is covered with this insulatinglayer). Because of the insulating layer, it is possible to connect alead (e.g., an alligator clip) to the outer portion of a given contactpad and address its associated electrode while the array is immersed insolution, without having to worry about reactions that can occur on thewires or peripheral contact pads. The insulating layer may be, forexample, glass, silica, alumina, magnesium oxide, silicon nitride, boronnitride, yttrium oxide, titanium dioxide, hardened photoresist, or othersuitable material known to be insulating in nature.

[0045] Once a suitable inert substrate was provided, in this casethermally oxidized single crystal silicon was selected,photolithographic techniques were used to design and fabricate electrodepatterns on it. By applying a predetermined amount of photoresist to thesubstrate, photolyzing preselected regions of the photoresist, removingthose regions that have been photolyzed (e.g., by using an appropriatedeveloper), depositing one or more metals over the entire surface andremoving predetermined regions of these metals (e.g. by dissolving theunderlying photoresist), intricate patterns of individually addressableelectrodes were fabricated on the substrate.

[0046] The fabricated arrays consisted of a plurality of individuallyaddressable electrodes that were insulated from each other (by adequatespacing) and from the substrate (fabricated on an insulating substrate),and whose interconnects were insulated from the electrochemical testingsolution (by the hardened photoresist or other suitable insulatingmaterial).

[0047] Materials were deposited on the above described electrode arraysto prepare a library of compositions by the electrodeposition of speciesfrom solution using standard electrochemical methods. More specifically,the depositions were carried out by immersing the electrode array in astandard electrochemical deposition chamber containing the array, aplatinum mesh counter electrode, and a reference electrode (e.g.,Ag/AgCl). The chamber was filled with a plating solution containingknown amounts of source material to be deposited. By selecting a givenelectrode and applying a predetermined potential for a predeterminedamount of time, a particular composition of materials (which may or maynot correspond to the exact composition of the plating solution) wasdeposited on the electrode surface. Variations in the compositionsdeposited may be obtained either by directly changing the solutioncomposition for each deposition or by using different electrochemicaldeposition techniques, or both. Examples of how one may change theelectrode composition by changing the deposition technique can include:changing the deposition potential, changing the length of the depositiontime, varying the counter anions, using different concentrations of eachspecies, and even using different electrochemical deposition programs(e.g., potentiostatic oxidation/reduction, galvanostaticoxidation/reduction, potential square-wave voltammetry, potentialstair-step voltammetry, etc.). In any event, through repeated depositionsteps, a variety of materials were deposited on the array.

[0048] After synthesizing the various alloy compositions on the array,the different alloys were screened for methanol oxidation to determinerelative catalytic activity against a standard alloy composition.

EXAMPLE 2

[0049] Using the procedures described in Example 1 to synthesizecatalyst compositions by electrodeposition, the following aqueous stocksolutions were prepared in 0.5 M sulfuric acid (H₂SO₄): 0.03 M platinumchloride (H₂PtCl₆), 0.05 M ruthenium chloride (RuCl₃), and 0.1 M nickel(II) bromide hydrate (NiBr₂.3H₂O). The sulfuric acid merely served as anelectrolyte thereby increasing the plating efficiency. A standardplating solution was created by combining 15 ml of the platinum chloridestock solution and 12 ml of the ruthenium chloride stock solution. Theelectrodes on the array were then immersed in the standard platingsolution. A potential of −0.93 V vs Ag/AgCl was applied for 2 minutes tothe first electrode (Electrode #1 in FIG. 3). The thickness of the layerdeposited on the electrode ranged from about 1500 and about 2000 Å. Thecomposition of the PtRu alloy plated under these conditions isrepresented by the formula Pt_(0.65)Ru_(0.35.)

[0050] To synthesize a PtRuNi ternary alloy composition, an aliquot ofthe nickel bromide stock solution (e.g., 0.2 ml) was added to thestandard PtRu plating solution and the second electrode was then platedat −0.93 V vs. Ag/AgCl for 2 minutes. The amount of nickel insubsequently deposited alloys was increased by adding nickel bromidestock solution to the plating solution. Thus, a library of alloycompositions can be created by varying the relative amounts of differentstock solutions in the plating solution (e.g., Electrodes #2-#11 in FIG.3 were plated under identical conditions except that the relativeamounts of the stock solutions were varied).

[0051] After synthesizing the various alloy compositions on the array,the different compositions were screened for methanol oxidation activityby placing the array into an electrochemical cell, which was filled witha room temperature solution of 1M methanol in 0.5 M H₂SO₄. The cell alsocontained in Hg/HgSO₄ reference electrode and a platinum mesh counterelectrode. Chronoamperometry measurements (i.e., holding a givenelectrode at a given potential and measuring the current that passes asa function of time) were then performed on all of the electrodes bypulsing each individual electrode to a potential of 0.3 V vs NHE (NormalHydrogen Electrode) and holding it there for about 6 minutes whilemonitoring and recording the current that flowed.

[0052] The alloy compositions on Electrodes #1, #2 and #3 were analyzedusing x-ray fluorescence (XRF) to determine their compositions. It iscommonly accepted that the chemical compositions determined using x-rayfluorescence are within about 5% of the actual composition. Electrode #1alloy contained about 65 atomic percent platinum, and about 35 atomicpercent ruthenium %. Electrode #2 alloy contained about 54 atomicpercent platinum, about 35 atomic percent ruthenium, and about 6 atomicpercent nickel. Electrode #3 alloy contained about 51 atomic percentplatinum, about 43 atomic percent ruthenium, and about 6 atomic percentnickel. Although the detection limit for a signal corresponding tonickel is about 6 atomic percent, concentrations of nickel below thatlevel can be estimated by comparing the relative intensity of the XRFspectra signals corresponding to platinum and ruthenium.

[0053] The data represented in FIG. 3 indicates that the PtRu binaryalloy on Electrode #1 and the PtRuNi ternary alloys on Electrodes #2-#11show methanol oxidation activity.

[0054] The activity of the most preferred ternary alloy,Pt_(0.54)Ru_(0.4)Ni_(0.06) (Electrode #2) was also compared to that ofPt_(0.65)Ru_(0.35) as a function of increasing voltage (see, FIG. 4).FIG. 4 indicates that the Pt_(0.54)Ru_(0.4)Ni_(0.06) alloy oxidizesmethanol at lower electrical potentials than the PtRu standard. Also,the Pt_(0.54)Ru_(0.4)Ni_(0.06) alloy has a greater catalytic activityfor a given potential than the standard.

[0055] It is to be understood that the above description is intended tobe illustrative and not restrictive. Many embodiments will be apparentto those of skill in the art upon reading the above description. Thescope of the invention should therefore be determined not with referenceto the above description alone, but should also be determined withreference to the claims and the full scope of equivalents to which suchclaims are entitled. The disclosures of all articles, patents andreferences, including patent applications and publications, areincorporated herein by reference for all purposes.

What is claimed is:
 1. A catalyst for use in electrochemical reactordevices, the catalyst containing platinum, ruthenium, and nickel,wherein the nickel is at a concentration that is less than about 10atomic percent.
 2. The catalyst of claim 1 wherein the catalyst is analloy.
 3. The catalyst of claim 1 wherein the concentration of nickel isat least about 1 atomic percent.
 4. The catalyst of claim 1 wherein theconcentration of nickel is at least about 2 atomic percent.
 5. Thecatalyst of claim 1 wherein the concentration of nickel is at leastabout 4 atomic percent.
 6. The catalyst of claim 1 wherein the platinumis at a concentration that is between about 40 and about 70 atomicpercent and the ruthenium is at a concentration that is between about 30and about 50 atomic percent.
 7. The catalyst of claim 6 wherein theconcentration of nickel is less than about 6 atomic percent.
 8. Thecatalyst of claim 1 wherein the platinum is at a concentration that isbetween about 45 and about 65 atomic percent and the ruthenium is at aconcentration that is between about 35 and about 50 atomic percent. 9.The catalyst of claim 8 wherein the concentration of nickel is less thanabout 6 atomic percent.
 10. The catalyst of claim 1 wherein the platinumis at a concentration that is between about 50 and about 60 atomicpercent and the ruthenium is at a concentration that is between about 40and about 50 atomic percent.
 11. The catalyst of claim 10 wherein theconcentration of nickel is less than about 6 atomic percent.
 12. Asupported electrocatalyst powder for use in electrochemical reactordevices, the supported electrocatalyst powder comprising a catalyst onelectrically conductive supports, the catalyst containing platinum,ruthenium, and nickel, wherein the nickel is at a concentration that isless than about 10 atomic percent.
 13. The supported electrocatalystpowder of claim 12 wherein the platinum is at a concentration that isbetween about 40 and about 70 atomic percent and the ruthenium is at aconcentration that is between about 30 and about 50 atomic percent. 14.The supported electrocatalyst powder of claim 13 wherein theconcentration of nickel is less than about 6 atomic percent.
 15. Thesupported electrocatalyst powder of claims 12 wherein the catalyst ispresent on the electrically conductive supports as metal alloy deposits.16. A fuel cell comprising an anode, a cathode, a proton exchangemembrane between the anode and the cathode, and a catalyst for thecatalytic oxidation of a hydrogen-containing fuel, wherein the catalystcontains platinum, ruthenium and nickel, wherein the nickel is at aconcentration that is less than about 10 atomic percent.
 17. The fuelcell of claim 16 wherein the concentration of nickel is at least about 1atomic percent.
 18. The fuel cell of claim 16 wherein the platinum is ata concentration that is between about 40 and about 70 atomic percent andthe ruthenium is at a concentration that is between about 30 and about50 atomic percent.
 19. The fuel cell of claim 18 wherein theconcentration of nickel is less than about 6 atomic percent.
 20. Thefuel cell of claim 16 wherein the catalyst is an alloy.